Figure 5.

7 Barrier with a Replaceable Fuse

Resistor Resistor Resistor Fuse

R3 R2 R1 F1

Hazardous Area
Z2 Z1 Safe Area

Figure 5.8: Typical Wiring for a Sinking Input

DC
Safe Area - Power
Supply
+
Barrier
Hazardous
Area
+ + 0
R3 R2 F1
Switch 1

Z2 Z1
- -
Comm.

Sinking
PLC
Input Card

Figure 5.9 : Sourcing Input (PLC input cards or other sourcing controllers)

DC
Safe Area - Power
Supply
+
Barrier
Hazardous
Area 0
+ +
R2 R1 F1 1
Switch

Z2 Z1
- -

Comm.

Sourcing PLC
Input Card

51
CHAPTER 5
Intrinsically Safe Equipment

Figure 5.10: Typical Sinking Circuit

Safe Area DC
- Power
Supply
Barrier
+
Hazardous
Area
+ + 0
R3 R2 F1
Fault 1
Fault

- Z2 Z1 -
Switch
High Potential
Guard Comm.

Sinking PLC
Input Card

Figure 5.11 Example of Operation Error due to Poor Grounding of the System

DC

Safe Area
- Power
Supply
+
Hazardous Barrier
Area
+ + 0
R3 R2 F1
1
Fault

- Z2 Z1 -
4-20mA
Transmitter
Comm.

Figure 5.12 Generic Switching Isolation Amplifier to be used with NAMUR Sensors and Dry Contacts

-
Integrated
Circuit
IC
Resistor
R
Fuse
F
~
Input from 120 VAC
Hazardous
Area
+ ~
Z Z Z C D
Optical
Isolation

Resistor

R
+
Output to the
Controller

52
Figure 5.13 Example MK13-UPF from TURCK’s Automation Catalog (page B7)

53
CHAPTER 5
Intrinsically Safe Equipment

Figure 5.14 Example MK13-UPF from TURCK’s Automation Catalog (page B8)

54
Notes:

55
CHAPTER 6
Nonincendive Methods for Division 2 Hazardous Locations

6.1 Terminology

Properly classified Division 2 locations aren’t often hazardous. They are essentially
‘buffer zones’ around Division 1 locations in which an explosive atmosphere will
never be present under normal conditions and only rarely as a result of unforeseen
equipment failures. If electrical faults in equipment occur fairly rarely, the risk of
these events happening simultaneously is negligible. However, acceptable
protection methods for Division 2 locations seem to be less widely understood than
those for Division 1 locations, despite the lesser hazard. This is partly due to the
fact that the somewhat cumbersome term ‘nonincendive’ is used to describe two
very different Class I, Division 2 protection methods:
• Nonincendive Equipment
• Nonincendive Circuits

6.2 Nonincendive Equipment

Simply put, if you supply nonincendive equipment with its rated power and use it per
its instructions, it won’t produce heat or sparks capable of igniting a hazardous
atmosphere. It must not have normally arcing contacts and must not produce heat
in excess of 80% of the ignition temperature of the hazardous atmosphere. There
is no fixed restriction on the amount of power as long as the preceding statement
remains true. The energy level carried by the interconnecting wiring may far
exceed the ignition curves. Therefore, a Division 2 wiring method must be used.
The acceptable methods may be found in NEC Article 501-4(b).

Quick disconnects are considered normally arcing if they don’t require a tool for
disconnection.

Benefits:
• No NRTL approved safety barrier, special enclosure or supply of
protective gas required.
• Higher power AC sensors can be approved as well as low power DC
sensors.

Drawbacks:
• A Division 2 wiring method must still be used.
• The sensor must be adaptable to a Division 2 wiring method.
• Quick disconnects are not allowed unless they require a tool for
disconnection.

56
Figure 6.1 summarizes the key Nonincendive Equipment concepts.

Figure 6.1 Nonincendive Equipment

HAZARDOUS LOCATION NON- HAZARDOUS LOCATION

Class I, Division 2

Nonincendive Hazardous Non-Hazardous Power

Field Device Location Wiring Location Wiring Supply

! NRTL Approved ! Power in wiring is ! Any suitable NEC ! Not NRTL approved
above ignition curve. wiring method.
! Power consumption Division 2 wiring ! Nominal ratings
exceeds the ignition method required per consistent with
curves NEC Article 501-4(b). field device
! No arcing contacts
! No excessive heat
! Adapatable to Division 2
wiring method

Figure 6.2 summarizes the key Nonincendive Circuit concepts.

Figure 6.2 Nonincendive Circuit

HAZARDOUS LOCATION NON- HAZARDOUS LOCATION

Class I, Division 2

Nonincendive Hazardous Non-Hazardous Power

Field Device Location Wiring Location Wiring Supply

! NRTL Approved
! Power consumption
is under the ignition
curves
! Energy level in wiring is below the ignition ! NRTL approved
curves. Any wiring method suitable for an
equivalent non-hazardous location is allowed. ! Output below the
ignition curves

! Contacts OK

! Quick disconnect OK

6.3 Nonincendive Circuits.

The electrical energy in a Nonincendive Circuit is incapable of igniting a specific

hazardous atmosphere under normal conditions. The concept is very similar to
intrinsic safety but with lower safety factors and no faults considered in equipment
examinations.

57
CHAPTER 6
Nonincendive Methods for Division 2 Hazardous Locations

The energy level carried by the interconnecting wiring is below the ignition curves
with a 10% margin. Therefore, any wiring method suitable for an equivalent
non-hazardous location is acceptable.

Quick disconnects are also permitted because their disconnection doesn’t result in
an ignition-capable spark.

Benefits:
• No special wiring.
• Quick disconnects allowed.
• Sensors that can’t be adapted to a Division 2 wiring method can be used.

Drawbacks:
• Only relatively low power devices can be used.
• The power supply must be NRTL approved.
• The wiring must be separated from other types.

6.4 Typical Installations

Figure 6.3 (pages 60-61) includes 6 examples that illustrate key nonincendive
concepts. In all cases, the wiring method must be sealed at the point of exit from
the hazardous area if it can transport hazardous gases into the non-hazardous
area. Examples of wiring methods that require sealing are: conduit, enclosed
wireways and busways, and large loosely packed multicore cables. Poured
explosionproof seals are not required in these applications. The seal is intended
only to protect against the transport of un-ignited gas with low differential pressure.
It is not intended to stop an explosion-induced flamefront under pressure.

Examples 1 - 4 depict sensors approved as nonincendive equipment. These

sensors could conceivably be powered by up to 250 VAC.

Examples 5 and 6 depict sensors used in nonincendive circuits. The sensors

used in such installations would necessarily need to operate on relatively low
power.

Example 1 Installation of a threaded cylindrical sensor using conduit.

A threaded cylindrical sensor may be wired to a rigid metal conduit system using a
thread adapter. The conduit must be sealed at the point it leaves Division 2. No

58
seal is required at the sensor and no NRTL approval for the non-hazardous location
device is required.

Example 2 Installation of a threaded cylindrical sensor using cable trays or

wireways.

Power limited tray cable (PLTC) or instrument tray cable (ITC) in cable trays may be
used for the home run from a sensor. However, the drop from the tray to the sensor
must use a Division 2 wiring method as well. The tray or wireway must be sealed
as it exits the Division 2 area if it is capable of transporting hazardous gases. This is
not necessary when the wireway is open or well ventilated as with ladders,
messenger wires, etc.

Example 3 Installation of a sensor with a terminal compartment using raceway.

The sensor may alternately have a terminal compartment with a threaded entry or
an entry that will accept a conduit hub. A raceway in this context could be a flexible
conduit system. PLTC or ITC cable must be used within the raceway. The raceway
must be sealed at the point it leaves Division 2.

Example 4 Installation of a slot sensor in a general purpose enclosure.

A sensor that has no terminal chamber or barrel threads and thus can’t be adapted
to a Division 2 wiring method may be used only if it is part of a nonincendive circuit,
as in 6, or is installed within an enclosure. If the latter method is used, the
enclosure need only be a general purpose enclosure meeting the requirements of
ANSI/ISA S82, requiring a tool to open, and providing a method to accommodate a
Division 2 wiring method, such as a conduit hub or knock-out. A common example
of such an installation is sensors used for valve position indication within a
dedicated enclosure.

Example 5 Installation of a sensor that has a quick disconnect.

A quick disconnect may be used if it is approved as part of a nonincendive circuit

and the power supply is also approved. The two devices may be approved as a
system or have compatible nonincendive field circuit parameters. No special wiring
method is required other than what would be required for an equivalent
non-hazardous location.

59
CHAPTER 6
Nonincendive Methods for Division 2 Hazardous Locations

Example 6 Installation of a sensor that can’t be adapted to Division 2 wiring

method.

A sensor that has no terminal chamber or barrel threads and thus can’t be adapted
to a Division 2 wiring method, may be used if it is approved as part of a
nonincendive circuit and the power supply is also approved. The two devices must
be approved as a system or have compatible nonincendive field circuit parameters.

Figure 6.3 Installation Examples of Nonincendive Equipment and Circuits

HAZARDOUS LOCATION NONHAZARDOUS LOCATION

Class I, Division 2
Equipment with nominal
ratings that match the
1 sensor nominal ratings.
NRTL approval not
required.
Conduit adapter Conduit Seal

NRTL approved nonincendive

proximity sensor without
nonincendive field circuit
input parameters

Equipment with nominal

ratings that match the
sensor nominal ratings.
2 NRTL approval not
required.
Cable tray or wireway system

Raceway
Thread adapter

NRTL approved nonincendive proximity sensor

- with terminal compartment
Equipment with nominal
- without nonincendive field circuit input parameters.
ratings that match the
sensor nominal ratings.
NRTL approval not
required.
Seal
PLTC or
3 ITC Cable
Raceway
Conduit hub

NRTL approved nonincendive proximity sensor

without nonincendive field circuit input parameters,
installed within a general purpose enclosure that
requires a tool to open.

Equipment with nominal

ratings that match the
sensor nominal ratings.
NRTL approval not
4 Seal
required.
Secure terminations Conduit hub Conduit

60